Sensor Alignment Using Magnetic Phase Shift at Shaft End
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Solution Overview
Problem
Existing methods for aligning sensor devices with magnetic targets are inefficient and often result in misalignment, as they often fail to efficiently address the inefficiencies in sensor alignment, as they fail to efficiently align sensor devices with rotation axes.
Innovation Solution
The method involves identifying magnetic field values generated by the target at various rotation angles, determining a phase shift angle, and using this information to align the sensor device with the target by calculating a movement vector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional calibration methods are used to align the sensor device, then the alignment process is simple to perform, but the alignment precision is insufficient and results in misalignment
Solution Approach 1:
The patent replaces manual mechanical alignment procedures with an automated electronic calibration process. The system uses electronic signals from the sensor device to detect the magnetic target's position and automatically calculates the required alignment adjustments, eliminating the need for manual mechanical positioning while achieving superior alignment precision.
Solution Approach 2:
The patent implements a feedback mechanism where the sensor device continuously monitors its own output signals during the calibration process. The system analyzes the sensor signals to determine the current alignment state, compares it with the ideal alignment condition, and automatically adjusts the sensor position or target orientation to achieve precise alignment. This closed-loop feedback enables high precision without complex manual procedures.
2Measurement precision
If the sensor device is positioned away from the rotation axis for ease of installation, then the installation process is simpler, but measurement accuracy deteriorates due to misalignment
Solution Approach 1:
The patent performs preliminary calibration actions before the sensor device is put into its final operational position. During this preliminary phase, the system characterizes the sensor's response to the magnetic target at various positions and creates a calibration model. This allows the sensor to be installed in convenient locations while the calibration data compensates for any positional deviations, maintaining measurement accuracy without sacrificing installation ease.
Solution Approach 2:
The patent changes the operational parameters of the sensor device based on its actual position relative to the rotation axis. By detecting the sensor's precise position and adjusting the measurement parameters accordingly, the system maintains measurement accuracy even when the sensor is not perfectly aligned with the rotation axis. This parameter adjustment compensates for positional deviations and eliminates the need for perfect installation alignment.
3Productivity
If manual alignment procedures are used, then the alignment process requires minimal equipment, but the alignment time is excessive and productivity is reduced
Solution Approach 1:
The patent enables the sensor device to perform its own alignment and calibration without requiring external alignment tools or manual intervention. The sensor device uses its inherent sensing capabilities to detect the magnetic target, automatically determines its misalignment state, and triggers the appropriate correction mechanisms. This self-service approach dramatically increases alignment speed while keeping the added complexity minimal, as the system leverages the sensor's own properties for calibration rather than requiring separate calibration equipment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for efficient alignment of the sensor device with the target, improving accuracy in measuring magnetic field strength and rotation angle, reducing alignment errors and enhancing measurement precision.
Implementation Method 1
identifying values related to a magnetic field generated by the magnetic target
Implementation Method 2
the values related to the magnetic field are identified based on signals generated by a Hall plate of the sensor device
Data Source
AI summary
Disclosed are example systems, methods, and techniques for positioning a sensor device. In particular, described are example systems, methods, and techniques for positioning a sensor device such that the sensor device is aligned with a rotation axis of a target. Using the systems, methods, and techniques disclosed herein, a sensor device may be centered over a rotation axis of a target in an end-of-shaft sensing application. The systems, methods, and techniques disclosed herein may be used to align a sensor device with a rotation axis of a target in a manner that is more efficient than traditional approaches for calibrating a sensor device.